KR20090094346A - Process for Dyeing a Textile Web - Google Patents

Abstract

In a process-for dyeing a textile web (23) having a first face and a second face opposite the first face, dye is applied to the textile web and the dyed web is then immersed in a flowing treatment liquid with the textile web in a generally open configuration. A contact surface of an ultrasonic vibration system (61) is immersed in the flowing treatment liquid with the contact surface in direct contact with at least a portion of the textile web immersed in the treatment liquid. The ultrasonic vibration system is operated to impart ultrasonic energy to the portion of the textile web immersed in the treatment liquid at the contact surface of the ultrasonic vibration system to facilitate the removal of unbound dye from the textile web for entrainment in the flow of treatment liquid.

Description

Process for Dyeing a Textile Web

FIELD OF THE INVENTION The present invention relates generally to a method for dyeing a textile web, and more particularly, to a method for dyeing a textile web that removes unbound dye from the web after initial dyeing of the web. will be.

The textile dyeing process applies dyes to the textile web with ink jet systems, spray systems, gravure rolls, slot dies, rod coaters, rotary screen curtain coaters, air knives, brushes or other suitable application systems or techniques and then onto the textile web. It typically involves heating and / or steaming the dyed textile web to facilitate binding of the dye to it. After the steaming operation, the textile web can be washed in a water or other cleaning solution bath to remove unbound (unbound) excess dye from the web. For example, in some cleaning processes, the textile web is immersed in a cleaning bath flowing on the web such that the cleaning liquid (typically water) washes off unbound dyes.

The washing sequence of this conventional textile dyeing process is often a relatively slow process, which is the diffusion of unbound dye molecules in the matrix of the textile web onto the surface of the textile where unbound dyes can be entrained in the flow of the wash liquor. because it depends on (diffusion). In addition, washing of the dyed textile in this manner may require several washings to remove the desired amount of unbound dye from the web.

It is also known to apply ultrasonic energy to textile webs during textile processing. For example, as described in US Pat. No. 4,302,485 (Last et al.), Sonication may be applied to a textile web while the web is immersed in a dye solution or other treatment solution bath, where ultrasonic energy is applied to the dye or Increase the penetration of other treatment solutions into the web. However, this process requires the use of a significant amount of dye (eg, the bath as a whole) relative to the amount of dye ultimately required in the web.

Therefore, there is a need for a dyeing method that reduces the amount of dye required for dyeing textile webs and / or can easily remove unbound dyes from the web during the process without removing the dyes that are already bound.

1 schematically shows a dye station and a textile web by one embodiment according to a textile web dyeing process by one embodiment showing an ultrasonic vibration system of a rinsing station of the apparatus as an immersion position of the vibration system. A schematic perspective view showing a dyeing apparatus;

2 is a side view of a rinsing station of the apparatus of FIG. 1;

FIG. 2A is a side view similar to FIG. 2 showing the ultrasonic vibration system in the retracted position of the vibration system; FIG.

3 is a front view of the ultrasonic vibration system of the apparatus of FIG. 1;

4 is a side view of these;

FIG. 5 is a schematic perspective view showing another embodiment of an apparatus for dyeing a textile web according to the dyeing process of the textile web indicated by the immersion position of the intensity system of the ultrasonic vibration system of the apparatus.

Corresponding reference characters indicate corresponding parts throughout the drawings.

According to one embodiment, a method of dyeing a textile web having a first side and a second side opposite to the first side generally comprises applying a dye to the textile web and generally opening configuration of the textile web. ), Immersing the dyed textile web in a flowing treatment liquid. The contact surface of the ultrasonic vibration system is immersed in a flowing treatment liquid in direct contact with at least a portion of the textile web where the contact surface is immersed in the treatment liquid. The ultrasonic vibration system facilitates the removal of unbound dye from the textile web entrained in the flow of treatment liquid, so that ultrasonic energy is applied to a portion of the textile web immersed in the treatment liquid at the contact surface of the ultrasonic vibration system. Act to give.

In another embodiment, a method of dyeing a textile web having a first side and a second side opposite the first side generally comprises applying a dye to the textile web and the treatment liquid such that the textile web is submerged in the treatment liquid. Directing the textile web into a holding tank containing. The treatment liquid flows from the tank inlet through which the treatment liquid flows into the tank into the tank outlet through which the treatment liquid is discharged from the tank. The contact surface of the ultrasonic vibration system is immersed in the treatment liquid in the tank in direct contact with at least a portion of the textile web immersed in the treatment liquid. The ultrasonic vibration system is adapted to impart ultrasonic energy to a portion of the textile web immersed in the treatment liquid at the contact surface of the ultrasonic vibration system to facilitate removal of unbound dye from the textile web, which is incorporated in the flow of treatment liquid. Function. The dye is filtered out of the treatment liquid after the treatment liquid is discharged from the holding tank.

In the drawings, in particular in FIG. 1, one embodiment of the apparatus used for dyeing textile web 23 is generally represented by 21. Textile webs 23 processed by device 21 include, but are not limited to, bonded-carded webs, spunbond webs and meltblown webs, polyesters, polyolefins, cotton, nylons, Silk, hydroknit, coform, nanofiber, fluff batting, foam, elastomers, rubber, film laminates, combinations of these materials or other suitable materials Suitable woven webs can include or non-woven webs. The textile web 23 may be a single web layer or a multilayer laminate, suitable for dyeing one or more layers of laminate.

The term "spunbond" is described, for example, in US Pat. No. 4,340,563 to Appel et al., US Pat. No. 3,692,618 to Dorschner et al., US Patent 3,802,817 to Matsuki et al., US Patent 3,338,992 to Kinney 3,341,394, US Pat. As described in US Pat. No. 3,542,615 to Dobo et al., The molten thermoplastic material is extruded as filaments from a plurality of fine, generally circular, spinneret capillaries having a diameter of the extruded filaments and then quickly It refers to a small diameter fiber formed by reducing. Spunbond fibers are generally not tacky when deposited on a collecting surface. Spunbond fibers are generally continuous and have an average diameter (from at least 10 samples) of greater than 7 microns, more particularly between about 10 and 20 microns.

The term “meltblown” refers to a generally hot, converging high speed gas (eg, air) through a plurality of fine, generally spherical die capillary that melts a thermoplastic material. Refers to fibers made by extruding into molten threads or filaments and thinning the filaments of the molten thermoplastic material to a microfiber diameter, with a reduced diameter. The meltblown fibers are then carried by the high velocity gas stream and deposited on the collecting surface to form a randomly dispersed meltblown fibrous web. Such a process is disclosed, for example, in US Pat. No. 3,849,241 to Butin et al. Meltblown fibers are microfibers, which may be continuous or discontinuous, generally have an average diameter of less than 10 microns and are generally tacky when deposited on a collecting surface.

Laminates of spunbond and meltblown fibers may, for example, sequentially deposit a spunbond web layer, then a meltblown web layer and finally another spunbond web layer, on a moving forming belt. depositing) and then bonding the layers together. Alternatively, the web layers can be made separately, collected in rolls, and combined in separate bonding steps. Such laminates generally have a basis weight of about 0.1 to 12 osy (6 to 400 gsm), or more particularly about 0.75 to about 3 osy.

The dyeing apparatus 21 shown in FIG. 1 comprises a dye station, schematically and generally 25, where dye is applied to the textile. As used herein, the term "dye" refers to a material that imparts some permanent color to other materials, such as textile web 23. Suitable dyes include, but are not limited to, inks, lakes (also sometimes called color lakes), dyestuffs (but not limited to, for example, acid dyes) acid dyes, azo dyes, basic dyes, direct dyes, disperse dyes, food, pharmaceutical and cosmetic dyes, ingrain dyes, leather dyes, Mordant dyes, natural dyes, reactive dyes, solvent dyes, sulfur dyes and vat dyes), pigments (organic and Inorganic) and other colorants (such as, but not limited to, fluorescent brighteners, developers, oxidation bases). Dye station 25 may be pre-metered for dyes (e.g., a slight excess of dye is applied during initial application of the dye or no excess dye is applied) or post-metered. ) (Ie, excess dye is applied to the textile web and subsequently removed.) To include any suitable device used to apply the dye to the textile web 23. It is understood that the dye itself may be applied to the textile web 23 or the dye may be used in the dye solution applied to the web.

Examples of suitable pre-measure dye application devices include, but are not limited to, devices capable of performing the following known application techniques:

Slot die: The dye is metered directly onto the textile web 23 through a slot in the printing head.

Direct gravure: The dye is present in a small cell of the gravure roll. The textile web 23 is in direct contact with the gravure roll and the dye in the cell is transferred onto the textile web.

Offset gravure with reverse roll transfer: Similar to the direct gravure technique except that the gravure roll transfers the coating material to the second roll. The second roll then comes into contact with the textile web 23 to transfer dye onto the textile web.

Curtain coating: This is a coating head with multiple slots. The dye is metered through this slot and falls down a given distance up to the textile web 23.

Slide coating: A technique similar to curtain coating except that upon exiting the coating head, multiple layers of dye are in direct contact with the textile web 23. There is no open gap between the coating head and the textile web 23.

Forward and reverse roll coating (also known as transfer roll coating): This is a stack of rolls that transfer dye from one roll to the next for weighing purposes. Is done. The final roll is in contact with the textile web 23. The direction of movement of the textile web 23 and the rotation of the final roll determine whether the process is a forward or reverse process.

Extrusion coating: This technique is similar to the slot die technique except that the dye is solid at room temperature. The dye is heated to the melting temperature in the print head and metered directly onto the textile web 23 with liquid through the slot. Upon cooling, the dye becomes solid again.

Rotary screen: The dye is pumped into a roll with a screen surface. A blade inside the roll exerts a force on the dye so that the dye is discharged through the screen and transferred onto the textile.

Spray Nozzle Application: A force is applied to the dye so that the dye is applied directly onto the textile web 23 via the spray nozzle. The desired amount of (pre-measured) dye can be applied, or the textile web 23 is saturated by a spraying nozzle and then excess dye can be squeezed by passing the textile web through a nip roller ( Post-metering).

Flexographic printing: The dye is transferred onto a raised patterned surface of the roll. The patterned roll is then contacted with the textile web 23 to transfer the dye onto the textile.

Digital textile printing: Dye is loaded into an ink jet cartridge and jetted onto the textile web 23 as the textile web passes under the ink jet head.

Examples of post-metering dye applicating devices suitable for applying the dye to the textile web 23 include, but are not limited to, devices operating according to the following known application techniques:

Rod coating: Dye is applied to the surface of the textile web 23 and excess dye is removed by the rod. Mayer rods are a common device for measuring and removing excess dye.

Air knife coating: Dye is applied to the surface of textile web 23 and excess dye is removed by blowing a high pressure air stream.

Knife Coating: Dye is applied to the surface of the textile web 23 and excess dye is removed by a knife shaped head.

Blade coating: Dye is applied to the surface of the textile web 23 and excess dye is removed by a head in the form of a flat blade.

Squeeze roll after dip coating (saturating): The textile web 23 is immersed in the dye and then pulled through the nip between the two rollers to squeeze out excess material.

Spin Coating: The textile web 23 is rotated at high speed and excess dye applied to the rotating textile web is spin-off from the surface of the web by centrifugal force.

Fountain coating: Dye is applied to the textile web 23 by a floated fountain head and excess material is removed by the blade.

Brush application: The dye is applied to the textile web 23 as a brush and the excess material is controlled by the movement of the brush across the surface of the web.

After applying the dye to the textile web 23, the dyed textile web can be transferred to a curing station, schematically and generally indicated at 27, which promotes binding of the dye to the textile web. To this end, the dyed textile web is subjected to heat treatment, steam treatment and / or other known curing treatments. However, curing station 27 may be omitted in dyeing apparatus 21, which is within the scope of the present invention.

In the embodiment shown, the dyed and cured textile web 23 is suitably generally in the form of a continuous web, more particularly in a rolled web, where the web is unrolled during processing and then again to be transported. It is wound. For example, after the textile web 23 has been dyed and cured, it is rolled up for transportation to a washing station, generally indicated at 31. Alternatively, however, the textile web 23 may be in the form of one or more discrete webs during processing and transportation, which is within the scope of the present invention. In addition, the web 23 can be fed from one station (eg curing station 27) to the next (eg washing station) without intervening transport, the web being unwound It remains state or otherwise opens as it is fed from one station to the next.

In washing station 31, the dyed and cured (and in the illustrated embodiment, rolled up) textile web 23 is conveyed in the machine direction through the washing station, whereby a washing process for washing the unbound dye in the web is provided. Is done. As used herein, the term “machine direction” generally refers to the direction in which the textile web 23 moves along the wash station (eg, the longitudinal direction of the web in the illustrated implementation). As used herein, the term "cross-machine direction" is a normal direction relative to the machine direction of the textile web 23 and is generally the plane of the web (eg, the illustrated implementation). Refers to the widthwise direction of the web.

According to one suitable embodiment, the washing station 31 comprises a holding tank 33 which comprises a suitable treatment liquid 35 which is open at the top and in which the textile web 23 is immersed during the cleaning process for washing and removing unbound dye from the textile web. For example, such a treatment liquid 35 may include water, a solution of a wash liquid other than water and water, or another suitable liquid solution that facilitates washing away unbound dyes from textiles. In a particularly suitable embodiment, however, it is suitable that the treatment liquid 35 does not contain dyes or other materials intended to be absorbed into the textile web 23 at the washing station 31.

However, it is understood that other treatments may be disposed in the treatment liquid. Examples of such treatments include, but are not limited to, alcohols, ketones, petroleum ethers, hydrocarbons, aromatics, surfactants, freons (halohydrocarbons), silicones, silicone polyethers, curing agents, fluoro Carbon, fluorescent agents, stabilizers, titanium dioxide, UV absorbers, fragrances, insect repellants, activated carbons, silica or carbonate and nanoparticle systems.

It is also understood that the top of the holding tank 33 does not have to be fully open or can be completely closed, which is within the scope of the invention. For example, instead, the web 23 can enter the holding tank 33 through one end wall of the tank and exit from the tank through the opposite end wall thereof.

In the illustrated embodiment of FIG. 2, the treatment liquid 35 is suitably flowed, swirled or otherwise stirred in the holding tank 33, and in a more suitable embodiment, the treatment liquid 35 is continuously into the tank and through the tank. And subsequently flow out of the tank. For example, the holding tanks of FIGS. 1 and 2 may be adapted to purge or otherwise operate inlet 37, outlet (not shown) and treatment liquid to flow from the inlet to the outlet in the tank. A device 39, wherein the treatment liquid 35 enters the tank through the inlet 37 and includes dye removed from the contaminated treatment liquid (e.g., textile web 23 entrained in liquid) through the outlet. Is discharged from the tank.

In a particularly suitable embodiment, the treatment liquid 35 is in the direction (eg, machine direction) in which the textile web 23 travels through the tank for cleaning, at least a fragment of the web being processed for any given time, which will be described in detail herein below. It is adjusted to flow in tank 31 in a generally opposite direction with respect to. For example, in the implementation shown in FIG. 2, the textile web 23 moves in the machine direction indicated by a single arrow in the tank 33 and the treatment liquid 35 flows in the direction indicated by the double arrow in the tank. However, it is understood that the treatment liquid 35 may flow in the same direction generally as the web 23 in tank 33 moves through the tank, which is within the scope of the present invention.

In another embodiment, instead, the treatment liquid 35 remains in tank 33 (eg, instead of being continuously fed to the tank) and is circulated to facilitate cleaning of unbound dye from the web or the tank relative to the web 23. It can be stirred in other ways. In this embodiment, the contaminated treatment liquid 35 may be intermittently drained or removed from the tank 33 and replaced with a clean treatment liquid.

In one particularly suitable embodiment, the treatment liquid 35 exiting from the tank 33 at the outlet of the tank is re-circulated back to the inlet 37 so that it is properly cleaned (ie, dye removed) and re-circulated through the tank so that the treatment liquid is more The washing station 31 is generally provided with a closed-loop system for efficient use. For example, in the implementation shown in FIGS. 1 and 2, the circulation device 39 includes a suitable circulation pump disposed outside of the tank 33 so as to flow in communication with the tank outlet, the treatment liquid 35 is discharged out of the tank and the treatment liquid is A closed-loop system that includes recirculation to tank inlet 37 operates to circulate into the tank in a desired direction, for example from the inlet to the outlet of the tank.

A suitable filter system 41 can be used in the exterior of tank 33 along the circulation path of treatment liquid 35, eg in order to filter or otherwise remove dyes and / or other contaminants from the treatment liquid before the treatment liquid is re-circulated back through the tank. For example, it is arranged in the middle of the pump 39 and the tank inlet 37. In another suitable implementation, for example, filter system 41 may be prepared from the "aqueous release" of US patent application Ser. No. 11 / 530,183, filed Sep. 8, 2006, which is incorporated by reference herein in its entirety. And the system described in Ultrasonic Treatment System for Separating Compounds from Aqueous Effluent. However, any filter system suitable for filtering dyes and other contaminants from the treatment liquid may be used within the scope of the present invention. In addition, one or more pressure gauges 43 are provided along the circulation path of the treatment liquid 35 to monitor (and adjust) the liquid pressure in the circulation path of the treatment liquid.

With reference to FIGS. 1 and 2, the unwind roll 45 is supported by a support structure 47 suitable to hold the wound textile web 23 dyed and in some embodiments cured. The corresponding wind roll 49 and associated drive mechanism 51 are supported vertically, for example towards the opposite end of the holding tank 31, at a distance from the unwind roll by an additional support structure 53. do. The driving mechanism 51 is suitably operated to pull the textile web 23 from the unwind roll 45 to the wind roll 49 along the machine direction of the web. The textile web then sonicates the web to remove unbound dye from the web. Is wound up again.

The ultrasonic vibration system, generally denoted 61, is at least partially immersed in the treatment liquid 35 in the holding tank 33 and the portion 23 or segment of the web immersed in the cleaning liquid 23 (ie, the wash liquid so that the vibration system imparts ultrasonic energy to the web). )) Has a contact surface 63 (FIG. 2) in contact with and through the vibration system. In the illustrated implementation, the ultrasonic vibration system 61 has a terminal end 65 and at least a portion of the terminal end 65 defines a contact surface 63 in contact with the textile web 23. In particular, with reference to FIG. 2, in the illustrated embodiment, the textile web 23 is directed from the unwind roll 45 toward the contact surface 63 (eg, at the terminal end 65 of the ultrasonic vibration system 61). Advancing to the approach angle A1 with respect to the longitudinal axis X and after passing over the contact surface, the web leaves the wind roll 49 from the contact surface towards the wind roll 49 with respect to the longitudinal axis X of the ultrasonic vibration system 61. (departure angle) Move away to B1.

In such an embodiment, the approach angle A1 of the textile web 23 is suitably in the range of about 1 to about 89 degrees, more suitably in the range of about 1 to 45 degrees, and even more suitably in the range of about 10 to about 45 degrees. . The departure angle B1 of the web 23 is suitably approximately equal to the approach angle A1 as shown in FIG. 2. However, the departure angle B1 may be larger or smaller than the approach angle A1 without departing from the scope of the present invention.

In the implementation shown in FIG. 1, the ultrasonic vibration system 61 is suitably mounted on the support frame 67 between the unwind roll 45 and the wind roll 49, and adjusts the contact surface 63 of the ultrasonic vibration system to the web 23 to be processed. This is suitably mounted on the support frame which is movable relative to the holding tank 33 and the unwind roll and the wind roll (eg vertically in the implementation shown in FIG. 1). For example, in FIG. 2A, the vibration system 61 is positioned vertically, as referred to herein as a withdrawn position, in which the terminal end 65 (and thus the contact surface 63) of the ultrasonic vibration system is held. Withdrawn from the treatment liquid 35 of the tank 33. Further, the textile web is disposed outside of the processing liquid 35 at the retracted position of the vibration system 61, but may be in contact with, but need not be in contact with, the contact surface 63 of the vibration system.

1 and 2 show an ultrasonic vibration system 61, referred to herein as an immersed position, in which the vibration system is located vertically lower than the retracted position. In this immersion position, the terminal end 65 (and thus the contact surface 63) of the vibration system 61 is immersed in the treatment liquid 35 together with at least a vertical piece or part of the textile web 23. In this implementation, the movement of the vibration system 61 from the retracted position to the immersion position causes the web 23 to descend into the processing liquid 35 at the contact surface 63 of the vibration system and to form the approach and departure angles A1, B1 of the web.

The movement from the retracted position to the immersion position of the ultrasonic vibration system 61 in this manner also applies or increases the tension to the textile web 23 along at least a segment of the web lying against the contact surface 63 of the vibration system. And the web is held between the unwind roll 45 and the wind roll 49. For example, in one implementation, the textile web 23 has at least a fraction of the web in contact with the contact surface 63 of the ultrasonic vibration system 61, with a uniform tension along its width, from about 0.05 pounds per inch of fabric width to about 3 per inch of fabric width. Uniform tension can be maintained in the pound range, more suitably in the range of about 0.1 pounds to 0.5 pounds per inch of fabric width.

In one suitable implementation, the contact surface 63 of the ultrasonic vibration system 61 is placed in the immersion position just below the surface of the treatment liquid 35 of the holding tank 33 so as to prevent unnecessary parts of the vibration system from being immersed unnecessarily. Immersion of the textile web directly below the treatment liquid surface also minimizes the amount of treatment liquid that must be used, which also allows smaller (ie, shallower) tanks to be used. For example, in one implementation, the contact surface 63 of the ultrasonic vibration system 61 is in the range of about 1 inch to about 5 inches below the surface of the treatment liquid 35 in the holding tank 33, more suitably about one inch of the surface of the treatment liquid in the holding tank. Is placed below. However, it is understood that the ultrasonic vibration system 61 can be more immersed in the treatment liquid 35, which is within the scope of the present invention.

Referring to FIG. 3, in one implementation the ultrasonic vibration system 61 is generally denoted 71 and in the illustrated implementation defines a terminal end 65 of the vibration system, in particular having a terminal end 73, which defines the contact surface 63 of the vibration system. Ultrasonic horns are suitably included. In particular, the ultrasonic horn 71 of FIG. 3 preferably has an ultrasonic bar (also often a blade horn) in which the terminal end 73 of the horn is generally extended, for example along its width w. ) Is a suitable configuration called). In one embodiment, the ultrasonic horn 71 is suitably of unitary construction in which the contact surface 63 defined by the terminal end 73 of the horn is continuous across the entire width w of the horn.

Moreover, the terminal end 73 of the horn 71 is suitably formed such that the contact surface 63 defined by the terminal end of the ultrasonic horn is generally flat and rectangular. However, the horn 71 may be formed such that the contact surface 63 defined by the terminal end of the horn has a shape other than rounder or flattened shape, which is within the scope of the present invention. The ultrasonic horn 71 suitably lies relative to the textile web 23 moving so that the terminal end 73 of the horn extends in the cross-machine direction across the width of the web. The width w of the horn 71 is a suitable size at least approximately equal to or greater than the width of the web at its terminal end 73.

To facilitate increased vibration displacement of the terminal end of the horn during ultrasonic vibration, the thickness t of the ultrasonic horn 71 (FIG. 4) is greater than the connection end 75 of the horn than the terminal end of the horn (i.e., Larger at the terminal end of the horn opposite terminal terminal 73). As an example, the ultrasonic horn 71 of the implementation shown in FIGS. 3 and 4 has a thickness t of about 1.5 inches (3.81 cm) at its connecting end 75, while the thickness at terminal end 73 is about 0.5 inches. (1.27 cm). The illustrated horn 71 also has a width w of about 6.0 inches (15.24 cm) and a length (eg height in the illustrated implementation) of about 0.5 inches (13.97 cm). The thickness t of the illustrated ultrasonic horn 71 tapers inward as the horn extends longitudinally towards the terminal end 73. However, as long as the horn defines the contact surface 63 of the vibration system 61 suitable for contact with the textile web 23 so that the horn imparts ultrasonic energy to the web, the horn 71 may be of other forms than those shown in FIGS. It is understood that this belongs to the scope of the present invention.

The ultrasonic vibration system 61 of the illustrated embodiment is arranged coaxially (e.g. vertically) with an ultrasonic horn, an ultrasonic horn 71 and a booster 77 connected at one end to the ultrasonic horn 71 at the connecting end 75 of the horn. And a converter 79 (also sometimes called a transducer) disposed coaxially with the booster and connected to the opposite end of the booster. The converter 79 is in electrical communication with a power source or generator (not shown) to receive electrical energy from the power source and convert electrical energy into high frequency mechanical vibrations. For example, one suitable type of converter 79 converts electrical energy into mechanical vibrations depending on the piezoelectric material.

The booster 77 is configured to amplify the amplitude of the mechanical vibrations imparted by the converter 79 (can be configured to reduce it if necessary). The amplified vibration is then imparted to the ultrasonic horn 71. It is also understood that the booster 77 may be omitted in the ultrasonic vibration system 61, which is within the scope of the present invention. The construction and operation of suitable power sources, converter 79 and booster 77 are well known to those skilled in the art and do not require any further details herein.

In one implementation, the ultrasonic vibration system 61 is at a frequency in the range of about 15 kHz to about 100 kHz, more suitably in the range of about 15 kHz to about 60 kHz, and even more suitably in the range of about 20 kHz to about 40 kHz. May be activated (eg by a power source). The amplitude (eg displacement) of the horn 71 and more particularly its terminal end 73 for ultrasonic vibration can be varied by adjusting the input power of the power source, As the input power increases, the amplitude generally increases. For example, in one suitable implementation, the input power ranges from about 0.1 kW to about 4 kW, more suitably about 0.5 kW to about 2 kW, and even more suitably about 1.5 kW. In another implementation, the amplitude (eg, displacement) at its terminal end 73 of horn 71 (eg, contact surface 63 of vibration system 61) is suitably in the range of about 0.0005 to about 0.007 inches.

In an operation according to one embodiment of the method of dyeing a textile web, the textile web 23 is dyed in a dyeing station, cured in a curing station as required, and then wound (cold) and transported onto the unwind roll 45 of the washing station 31. Mounted. As the web passes under the terminal end 65 of the ultrasonic vibration system 61, the initial length of the web 23 is unwinded on the unwind roll 45 and winded onto the wind roll 49. In this step, the ultrasonic vibration system 6 is in the retracted position as shown in FIG. 2A. The ultrasonic vibration system 61 is then moved to an immersion position where the terminal end 65 (and thus the contact surface 63) of the vibration system and the fragment of the textile web 23 come into contact and move into the processing liquid 35 of the holding tank 33 (eg, FIG. 2). Lowered in the implementation shown). In addition, the textile web 23 may be tensioned by movement of the vibration system to the immersion position and / or by additional winding of the wind roll 49, by rewinding of the unwind roll 45, or both. Positioning the vibration system 61 to the immersion position also allows the textile web 23 between the unwind and the wind rolls 45 and 49 to define the approach angle A1 and departure angle B1 of the web with respect to the vertical axis X of the ultrasonic vibration system.

The textile web 23 is suitably disposed between the unwind roll 45 and the wind roll 49 in a form generally referred to herein as an open configuration. The term “open configuration” means that the textile web 23 is generally flat or in other words unfolded, ungathered and in at least a segment of the web in contact with the contact surface 63 of the vibration system 61. It is intended to mean untwisted. The drive mechanism 51 associated with the wind roll 49 is then operated along the approach angle A1 to pull the textile web 23 from the unwind roll 45 into the holding tank 33 and more specifically into the processing liquid 35. The textile web 23 passes across the contact face 63 of the ultrasonic vibration system 61, ie in contact therewith, in the machine direction of the web, and then further away from the contact face of the vibration system along the departure angle B1 towards the wind roll 49. Is pulled.

The feed rate of the web 23 (ie the speed at which the web moves in the machine direction at the contact surface 63 of the vibration system 61) and the width of the contact surface (ie the thickness t of the terminal end 73 of the horn 71 in the illustrated embodiment or the If the contact surface is flat or not flat, the total length of the contact surface from one side of the terminal end of the horn to the opposite side thereof) Determine what is referred to herein as the dwell time for the contact surface of the vibration system of the web. And as used herein, the term "dwell time" is understood to refer to the length of time that a piece of textile web 23 contacts the contact surface 63 of the vibration system 61 as the web is drawn to the contact surface. (Eg, the width of the contact surface divided by the feed rate of the web). In one suitable implementation, the feed rate of the web 23 across the contact surface 63 of the vibration system 61 ranges from about 0.5 feet / minute to about 2,000 feet / minute, more suitably from about 1 feet / minute About 100 feet / minute, and even more suitably, about 2 feet / minute to about 10 feet / minute. However, the feed rate may be in a range other than the above range, which is understood to fall within the scope of the present invention.

In other embodiments, the residence time suitably ranges from about 0.1 seconds to about 60 seconds, more suitably about 1 second to about 10 seconds, and even more suitably about 2 seconds to about 5 seconds. However, the residence time is for example a treatment liquid 35 comprising the material from which the web 23 is made, the dye composition, the frequency and vibration amplitude of the horn 71 of the vibration system 61, the circulation rate of the liquid in the tank 33 and the composition thereof and And / or other factors, as described above, and are understood to be within the scope of the present invention.

The treatment liquid 35 in the holding tank 33 is suitably circulated to flow against the textile web 23 and the ultrasonic vibration system 61, for example from the inlet 37 to the outlet in the illustrated embodiment. The flow rate of the treatment liquid in the holding tank 33 is generally sufficient to keep the cleaning treatment liquid flowing continuously through the contact surface 63 of the ultrasonic vibration system 61. However, in some cases it may be less efficient (eg to extract and remove dyes from textile web 23), but partially contaminated treatment solution 35 (eg, dyes removed from textile web 23 may be incorporated into the treatment liquid). Can flow across the contact surface 63 of the ultrasonic vibration system 61, which is within the scope of the present invention. By way of example, in one embodiment, the flow rate of treatment liquid 35 in the holding tank ranges from about 0.1 to about 50 gallons / minute, more suitably about 0.5 to about 10 gallons / minute, and more suitably From about 1 to about 5 gallons / minute.

The ultrasonic vibration system 61 is also activated by a power source such that the ultrasonic horn 71 is vibrated by ultrasonic waves as the web is pulled at the contact surface of the vibration system. Horn 71 imparts ultrasonic energy to a piece of textile web 23 in contact with contact surface 63 defined by terminal end 73 of the horn. In one suitable embodiment, the dye is applied to the textile web 23 at dye station 25, generally only on one side of the web, the web being in contact with the same surface as described above facing the contact surface 63 of the ultrasonic vibration system 61 at washing station 31. Is arranged to be. The application of ultrasonic energy to the web 23 at the surface facilitates the movement of the unbound dye in the web toward at least the same web surface and, more suitably, is exposed to the flow of treatment liquid 35 to expose the web. There is a tendency to move to discharge toward both sides of the.

However, it is understood that the opposite side (surface) of the web 23 (ie the opposite side to the side to which the dye was initially applied) may be in contact with the contacting surface 63 of the vibration system 61, which is within the scope of the present invention. It is also understood that a second ultrasonic vibration system (not shown) can be used simultaneously or sequentially with the first ultrasonic vibration system 61 to apply ultrasonic energy to the opposite side of the web. In another implementation, a second holding tank (not shown) can be disposed downstream (eg, machine direction) of the holding tank 33 and opposite the web against the face in contact with the first ultrasonic vibration system 61. A second ultrasonic vibration system (not shown) to impart ultrasonic energy to the surface of 23.

Unbound dye that is on and / or migrates to the surface of the textile web 23 is incorporated in the flow of treatment liquid 35 and transported away from the textile web. In the embodiment shown, the contaminated treatment liquor is then discharged from the holding tank 33 via the outlet, after which the dye is filtered from the treatment liquor 35 by the filtration system 41 and the treatment liquor is passed through the inlet 37 and the holding tank. It is recycled again. In other implementations, the contaminated treatment liquor discharged from the tank may be directed to a suitable drain, sewage, wastewater or recovery system. After treatment by washing station 31, textile web 23 is removed from the washing station for subsequent processing, if necessary.

5 shows a second implementation of the device, generally designated 121, used for dyeing textile web 123. The device 21 of the second embodiment is a pair supported by a suitable support structure 189 and arranged to face one side of the ultrasonic vibration system at a distance from the unwind and wind rolls 145, 149 in the machine direction of the web 123 in the machine direction. It further comprises a guide roll 185, 187 of which is substantially similar to the device 21 of the first implementation of FIGS. The guide rolls 185, 187 can easily apply the desired tension to the textile web 123, and the arrangement of the web relative to the ultrasonic vibration system 161 when the web is fed through the treatment liquid in contact with the contact surface of the ultrasonic vibration system. It is generally kept appropriate.

Test 1

Textile web dyeing effect of a device constructed as device 21 of the implementation according to FIGS. 1 and 2 and more particularly in a cotton textile web dyed and cured without removal of the combined dye from the undesirable web. A test was conducted to evaluate the effect of washing station 21 of this device on the removal of unbound dyes. In this test, three identically manufactured woven cotton web specimens were used. The specific web material used was Test No., West Pittston, Pennsylvania, USA. 419- Commercially available as a bleached, mercerized, combed broadcloth. Each web had a basis weight of about 120 grams per square meter and a weight of about 15.53 grams. Each web specimen was about 4 feet long (about 122 cm) and 4 inches wide (about 10.2 cm).

The dye solution is 10.1 grams of red dichlorotriazine dye (typically referred to as fiber-reactive dye) commercially available under the trade name and model number Procion MX-5B from Dystar Textifarben Gmbh, Germany, 10.2 grams of sodium carbonate and water Formed at 1000 grams. The solution was poured into an open holding tank. Place each web specimen in rolled form on an unwide roll and unroll the dyeing solution bath at a feed rate of about 4 ft./min (approximately 2.03 cm / sec) by means of a suitable wind roll and drive mechanism. It was pulled continuously through the bath (ie, dip-coated) and then wound up again on the wind roll. Each wound and dyed web was then placed in a sealed bag at room temperature for about 12-15 hours to facilitate dye binding to the textile web.

The wash station used for this test included enough holding tanks to hold at least 500 ml of water. Water did not circulate in the tank during the test.

The various components used in the ultrasonic vibration system are described in St. Illinois, USA. Commercially available from Dukane Ultrasonics of Charles under the following model number: power supply-model 20A3000; Converter-model 110-3123; Booster-model 2179T; And horn model 11608A. In particular, the horn is about 1.5 inches (3.81 cm) thick at its connecting end, about 0.5 inches (1.27 cm) thick at its terminal end, about 6.0 inches (15.24 cm) wide and length (e.g. , In the illustrated implementation), was about 5.5 inches (13.97 cm). The contact surface defined as the terminal end of the horn was flat and the length of the contact surface (eg approximately equal to the thickness at the terminal end of the horn) was about 0.5 inch (1.27 cm).

For each web specimen to be tested, 500 ml of room temperature clean water was poured into the holding tank. In a manner similar to that described above in connection with the cleaning station of FIGS. 1 and 2, the wound and dyed web specimens are placed on an unwind roll and the web passes water below about 1 inch (about 2.54 cm) of the water surface. Pulled into and through the water by a suitable wind roll and drive mechanism. A uniform tension of about 5 lbs was applied to the web (eg by keeping the web firmly between the wind and unwind rolls while pulling the web). The feed rate of the web was about 4 feet / minute (about 2.03 cm / sec.).

After the first pass of the web through the water, water was removed from the holding tank. The total amount of water and dye solution in the removed water was measured. The amount of dye solution removed from the web by the first pass was then calculated by subtracting 500 ml from the total amount of water and dye solution.

After the first wash, the wound sample web was hand-washed in the usual manner in 500 ml of clean water to further remove any unbound dye (if still present) from the textile web. The total amount of water and dye solution in the water was then measured. The amount of additional dye solution removed from the web was then calculated by subtracting 500 ml from the total amount of water and dye solution. The hand-wash process was repeated until the water was visually clean after washing.

For the first specimen, the passage through the washing station was done without applying any ultrasonic energy to the water or the web. For the second specimen, the ultrasonic vibration system was operated at about 2 kW and vibrated at about 20 kHz, the web being in direct contact with the contact surface of the horn of the vibration system, for example, for a residence time of about 0.63 seconds Passed. For the third specimen, the ultrasonic vibration system was operated at about 0.5 kW and vibrated at about 20 kHz, and the web was brought into direct contact with the contact surface of the horn of the vibration system, for example, for a residence time of about 0.63 seconds. Passed.

The results for the first and second specimens were as follows (except for the last treatment for each specimen since there was substantially no dye solution removed by the last treatment):

 Removed Dye Solution Washing stations (grams) Hand-grams Hand-grams Hand-grams Grams Percent removed from wash station Ultrasonic off 0.003 0.015 0.004 0.003 0.025 12 percent Ultrasonic on (2kw, 20kHz) 0.018 0.012 --- --- 0.030 60 percent

Thus, the direct application of ultrasonic energy to the web substantially increased the amount of unbound dye solution that could be removed from the web during the first pass through the wash station. However, the total amount of unbound dye removed by using ultrasound in the first pass was relatively close to the total amount of dye solution removed without ultrasound. Regarding the amount of unbound dye removed from the web during the first hand wash after sonication to the web, the results indicate that the previously bound dye from the web is not removed by sonication. The third specimen, performed at less input power (and thus resulting in a smaller horn displacement amplitude) gave substantially the same results as the second specimen.

From the above test results, it is understood that the textile web can additionally pass through the cleaning station one or more times to further remove unbound dye from the web using ultrasound. For example, referring to the washing station 31 shown in FIGS. 1-2, the wound web 23 can be removed from the wind roll 49 and placed on the unwind roll 45 again so that the web passes through the same washing station again. can do. Also, a second holding tank (not shown, but substantially the same as holding tank 33) and an ultrasonic vibration system (not shown, but substantially the same as vibration system 61) can be disposed downstream of holding tank 33 Thus, after treatment in the first holding tank, the web 23 is pulled further into the second holding tank further downstream to be subjected to a second sonication to further remove the unbound dye from the web.

Test 2

Tests were conducted to evaluate the effect of applying ultrasonic energy directly to the cotton textile web. In this test, two identically manufactured woven cotton web specimens were used. A web specimen of the same structure as the web specimen of Test 1 was used. During this second test the specimen remained unstained. The wash station for this test was the same as the wash station used in test 1.

For each web specimen to be tested, 500 ml of room temperature clean water was poured into the holding tank. The wound web specimen is placed on an unwind roll and the web is about 1 inch (about 2.54 cm) of the water surface using a wind roll and drive mechanism suitable for the web to pass water below about 1 inch (about 2.54 cm) of water. Pulled into and through the water to pass underneath. A uniform tension of about 5 lbs was applied to the web (eg by keeping the web firmly between the wind and unwind rolls while pulling the web). The feed rate of the web was about 4 feet / minute (about 2.03 cm / sec.).

After the first pass of the web through the water, water was removed from the holding tank and filtered to remove all cotton fibers from the water. The cotton fibers were then dried and weighted to determine the amount of fiber material removed from the web specimens. 500 ml of fresh fresh water was poured into the holding tank and the web specimen was placed back on the unwind roll and passed through the water again. The process was also repeated for three passes.

For the first specimen, the ultrasonic vibration system was operated at about 2 kW and vibrated at about 20 kHz, and the web passed directly through the water in direct contact with the contact surface of the horn of the vibration system, for example for a residence time of about 0.63 seconds. It became. For the second specimen, the ultrasonic vibration system was operated at about 0.5 kW and vibrated at about 20 kHz (for example, the resulting amplitude of the displacement of the horn was reduced), and the web was connected to the contact surface of the horn of the vibration system. For example, it was passed through water in direct contact for a residence time of about 0.63 seconds.

In the first specimen (eg, the ultrasonic vibration system was operated at higher input power, and therefore at greater amplitude), about 0.087 grams of cotton fibers were removed from the web in the first pass. In the second specimen (the ultrasonic vibration system was operated at a lower input power, and therefore at a smaller amplitude), only about 0.02 grams of cotton fibers were removed from the web in the first pass. That is, about one fifth of the fiber amount was removed by operating the ultrasonic vibration system at a lower input power than when operating at higher input power.

In describing the components of the present invention or the preferred implementation thereof, "a, an" and the term "the, said" are intended to mean one or more components. The terms "comprising, including" "containing" and "having" are inclusive and are intended to mean that there may be additional components other than the described components.

Various modifications to the above structure and method are possible within the scope of the present invention, and all details contained in the details described and shown in the detailed description and drawings of the invention are intended to be interpreted by way of example and not limitation. .

Claims (21)

Applying the dye to the textile web; Immersing the dyed textile web in an open configuration of the textile web, generally in a flowing treatment liquid; Immersing a contact surface of the ultrasonic vibration system in the flowing treatment liquid by directly contacting at least a portion of the textile web immersed in the treatment liquid; And Impart ultrasonic energy to the portion of the textile web immersed in the treatment liquid at the contact surface of the ultrasonic vibration system to facilitate removal of unbound dye from the textile web for entrainment in the flow of treatment liquid. Operating an ultrasonic vibration system so as to have a first side and a second side opposite said first side. The method of claim 1, wherein applying the dye to the textile web comprises applying a dye to the first side of the textile web, and immersing the contact surface of the ultrasonic vibration system in the flowing treatment liquid. And immersing a contact surface of an ultrasonic vibration system in direct contact with said flowing surface with one of said first and second surfaces of said textile web. 3. The method of claim 2, wherein the dipping of the contact surface of the ultrasonic vibration system into the flowing treatment liquid comprises dipping the contact surface of the ultrasonic vibration system into the flowing treatment liquid by directly contacting the first surface of the textile web. Method comprising the steps. 2. The method of claim 1, wherein immersing the dyed textile web in a flowing treatment liquid comprises moving the web in its machine direction within the flowing treatment liquid. The method of claim 4, wherein the processing liquid flows in a flow direction, and the moving of the web in a machine direction includes moving the web in a machine direction different from the flow direction of the flowing processing liquid. Way. 5. The method of claim 4, wherein moving the web in a machine direction comprises moving the web in a machine direction opposite to the flow direction of the flowing processing liquid. The method of claim 1, wherein the immersing the dyed textile web in the processing liquid flows directly from the upstream location where the textile web is disposed outside the flowing processing liquid. Moving the web in a machine direction to a position in the flowing processing liquid that is in contact, the method further comprising moving the web in a machine direction to a downstream position outside of the flowing processing liquid. 8. The ultrasonic vibration system of claim 7, wherein the ultrasonic vibration system has a vertical axis and the textile web generally approaches the vertical axis of the ultrasonic vibration system from the upstream position to the position in direct contact with the contact surface of the ultrasonic vibration system. Moving along an angle, wherein the approach angle ranges from about 1 to about 89 degrees. The method of claim 8, wherein the approach angle ranges from about 10 to about 45 degrees. The apparatus of claim 8, wherein the textile web moves from the position in direct contact with the contact surface of the ultrasonic vibration system to the downstream position along a deviation angle with respect to the vertical axis of the ultrasonic vibration system, wherein the deviation angle is about 1. To about 89 degrees. The method of claim 10, wherein the departure angle is substantially the same as the approach angle. The textile web of claim 1, wherein the textile web has a width and the method is uniform across the width of the textile web to a portion of the textile web that is in direct contact with the textile web at least in contact with the contact surface of the ultrasonic vibration system. Maintaining a tension, wherein the tension ranges from about 0.05 to about 3 pounds per inch of width of the textile web. The method of claim 1, wherein the ultrasonic vibration system vibrates at a frequency in the range of about 20 kHz to about 40 kHz. The method of claim 1, wherein the ultrasonic vibration system has a displacement amplitude at the contact surface upon its vibration, wherein the amplitude ranges from about 0.0005 to about 0.007 inches. The method of claim 1, wherein operating the ultrasonic vibration system comprises supplying power input to the system, wherein the power input ranges from about 0.5 kW to 2 kW. The ultrasonic web of claim 1 wherein the textile web has a width and the ultrasonic vibration system comprises an ultrasonic horn having a terminal end defining the contact surface, the terminal end of the ultrasonic horn being approximately equal to the width of the web. The step of immersing the contact surface of the ultrasonic vibration system in contact with the at least a portion of the textile web immersed in the treatment liquid in the flowing treatment liquid has a width equal to or greater than the width of the web. Disposing the ultrasonic horn such that the terminal end extends in a widthwise direction across a width of the web having a contact surface in direct contact with the web. 17. The method of claim 16, wherein the ultrasonic horn is of unitary construction extending continuously along at least its width at the terminal end of the ultrasonic horn. Applying the dye to the textile web; Directing the textile web into a holding tank containing the processing liquid such that the textile web is immersed in the processing liquid; Flowing the processing liquid in the holding tank from an inlet of the tank into which the processing liquid flows into the tank and into the outlet of the tank where the processing liquid is discharged from the tank; Contacting the contact surface directly with at least a portion of the textile web immersed in the treatment liquid, so as to immerse the contact surface of the ultrasonic vibration system in the treatment liquid in the tank; Impart ultrasonic energy at the contact surface of the ultrasonic vibration system to the portion of the textile web immersed in the treatment liquid to facilitate removal of unbound dye from the textile web for entrainment in the flow of treatment liquid. Operating the ultrasonic vibration system so as to; And Filtering the dye in the treatment liquid after the treatment liquid is discharged from the holding tank. 2. A method of dyeing a textile web having a first face and a second face opposite the first face. 19. The method of claim 18, comprising, after filtering the dye in the treatment liquid, re-circulating the treatment liquid back to the inlet of the holding tank. 19. The method of claim 18, wherein applying the dye to the textile web comprises applying a dye to the first side of the textile web, and immersing the contact surface of the ultrasonic vibration system in the flowing treatment liquid. Immersing the contact surface of the ultrasonic vibration system in the flowing treatment liquid such that the contact surface is in direct contact with one of the first and second surfaces of the textile web. 21. The method of claim 20, wherein immersing the contact surface of the ultrasonic vibration system in the flowing processing liquid so as to immerse the contact surface of the ultrasonic vibration system in the flowing processing liquid such that the contact surface directly contacts the first surface of the textile web. Method comprising the steps of: